Method of making wheel covers



Feb. 14, 1961 e. A. LYON METHOD OF MAKING WHEEL COVERS Original Filed April 29, 1955 2 Sheets-Sheet 1 Geo/ye A/berf 11/022 Feb. 14, 1961 G. A. LYON METHOD OF MAKING WHEEL COVERS Original Filed April 29, 1955 2 Sheets-Sheet 2 IHZEIYZUF 6 07a fl/Jer/ lye??? Unite METHOD OF MAKING WHEEL COVERS George Albert Lyon, 13831 W. Chicago Blvd, Detroit, Mich.

8 Claims. (Cl. 113-116) The present invention relates to the manufacture of wheel trim or covers such as are adapted to be applied to the outer sides of vehicle wheels for ornamental and protective purposes.

The present application is a continuation-impart of my application Serial No. 371,839, filed August 3, 1953, now Patent No. 2,707,449, dated May 3, 1955, and is a division of my application Serial No. 504,978, filed April 29, 1955 now Patent No. 2,921,548, dated January 19, 1960.

In my said copending patent is disclosed and claimed a method of making wheel trim or covers from sheet metal stock provided with marginal self-retaining fingers on a cold worked, resilient axially inwardly directed flange behind the mar in of the cover, and with a rib or fold turned laterally and radially outwardly through and beyond the circle of the flange to increase the overall diameter of the cover and conceal the retaining means therebehind.

Where the retaining flange and the finger extensions must be of a length to maintain the outer marginal portion of the cover substantially spaced from the' tire rim to which the cover is attached by means of the fingers, the retaining flange and fingers may be of such depth and length as to be unduly flexible and thus fail to retain the cover adequately at least under severe jarring or extraneous pressures against the cover in'service, this in spite of the substantial cold working and thereby hardening and resiliency imparted to the flange and fingers incident to practice of the method in my aforesaid application.

I now find that this deficiency insofar as extra deep flange and long fingers is concerned can be remedied by additionally working and stiffening portions of the retaining flange intermediate the retaining fingers, and it is to this improvement that the present application is directed.

It is accordingly an important object of the present invention to provide an improved methodof making wheel trim wherein additional resiliency is worked into a retaining flange adjacent to retaining finger extensions therefrom in order to reduce the inherent flexibility of the fingers and flange, to thereby increase the resilient tensioned retaining engagement characteristics of the fingers with a wheel part.

Another object of the invention is to improve the method of making wheel trim by substantially increasing the work hardened resiliency characteristics of the marginal portions of the trim including retaining flange and finger means thereon.

Another object of the invention is to provide an improved method of providing wheel trim with combination retaining finger, reenforcing and stop means for cooperation in retaining the trim in a predetermined mounted relation upon a vehicle wheel.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment thereof rates Patent taken in conjunction with the accompanying drawings in which:

Figure 1 is an outer side elevational view of a vehicle wheel structure embodying a cover or trim made according to the present invention;

Figure 2 is an enlarged fragmentary radial sectional view taken substantially on the line II-II of Figure 1;

Figure 3 is a fragmentary rear elevational view of a mar inal portion of the cover of Figure 2;

Figure 4 is a fragmentary vertical radial sectional view through a cover blank showing the same in a preliminary stage in the drawing thereof and more particularly in the drawing of the marginal portion thereof;

Figure 5 shows the same blank in a further stage in the shaping thereof; and

Figure 6 shows the blank in yet a further stage of the formiru of the marginal portion thereof and just prior to completing the marginal formation.

In order best to understand the advantages of the present invention, reference is made first to Figures 1, 2 and 3 showing a completed cover 10 made according to the present invention and adapted for disposition at the outer side of a vehicle wheel including a wheel body 11 provided with an annular outer marginal deeply dished portion 12 from which projects at the radially outer'side thereof but generally axially outwardly directed attachment flange 13 secured in suitable manner to a base flange 14 of a tire rim. Projecting generally radially outwardly from the outer side of the base flange is a side flange 15 merging with an intermediate generally axially outwardly and radially sloping flange 17 from the outer side of which extends generally radially outwardly and axially outwardly turned a terminal flange 18. The tire rimsupports a pneumatic tire 19 which may be of the tubeless type as shown or a tire and tube assembly.

The wheel cover 10 takes advantage of the substantial depth of the wheel inside of the tire rim to afford a deep draw, massive appearance, which is accentuated by the provision of a high central crown portion 20, a deeply indented annular intermediate portion 21 adapted to extend well down within the groove defined by the inwardly dished annular wheel body portion 12, and an annular radially outer portion 22 that projects substantially axially outwardly into axially outwardly overlying relation to the tire rim.

A reenforced stiflly resilient marginal structure and improved retaining means therebehind are provided on the cover 10. To this end, the outer marginal extremity on the cover comprises an annular reenforcing rib marginal extremity 23 on the outer cover portion 22 having nested therebehind an unturned flange portion 24 joined thereto on a reenforcing and finishing bead-like extremity, juncture 25. For retaining the cover on the wheel, the underturned flange 24 has a generally axially extending flange portionq27 from which projects an annular series of circumferentially spaced retaining finger extensions 28 provided at their inner terminals with short and stiff generally radially and axially outwardly oblique rim engaging legs or terminals 29 the edges of which are grippingly engageable with the inner face .of the intermediate flange 17 for retaining the cover on the Wheel.

Since to enable the desired substantial axially outward spacing of the outer marginal flange structure 23, 24 relative to the terminal flange 18 of the tire rim, it is desirable to have the flange 26 and the retaining fingers 2-8 of substantial depth or length, it will be appreciated that substantial flexibility will be experienced for radial deflection of the fingers and contiguous portions. of the flange 27. Therefore to reenforce and enhance the resiliency of the flange and fingers there are provided in line with arcuate cut-outs 30 between the retaining fingers 28, generally axially extending and radially outwardly projecting reenforcing corrugations 31 which flare toward the inner edge extremity of the flange 27 and attain maximum radially outward projection at their inner extremities. At their sides the flaringly transversely arcuate corrugations 31 merge with the sides of contiguous retaining fingers 28. At their axially outer ends the reenforcing corrugations 3d. merge into the juncture of the flange portion 27 with the flange 24 adjacent to a backup annular reenforcing rib 32 at the radially inner side of the rib marginal portion 23 and cooperating with the axially outer side of the flange 27 for stiffening the flange in cooperation with the corrugations 3 1.

In addition to serving as resiliency enhancing reenforcement, the corrugations 31 provide cover supporting stops for maintaining the cover in axially inward disposition and centered on the wheel by engagement with a shoulder 33 at the juncture of the intermediate flange 17 with the terminal flange 18. This is enabled by having the corrugations 31 project substantially radially outwardly at their inner terminals beyond the diameter described about the tips of the retaining finger terminal flanges 29. Therefore, when the cover is pressed axially inwardly onto the wheel to cam the retaining terminals 29 onto the intermediate flange inner face of the tire rim, the corrugation terminals will bear against the shoulder 33 and limit the axially inwardly disposition of the cover relative to the wheel and support the cover in spaced relation not only to the tire rim but also the wheel body 11.

To facilitate removal of the cover from the wheel, and to further stiffen the corrugations 31, the tip extremities of the corrugations are turned outwardly as at 34. Thereby when the stop-corrugations 31 are in engagement with the shoulder 33, a slight gap will remain between the turned central tip portions 34 and the tire rim for engagement thereunder of a pry-off tool by which the Cover is adapted to be removed from the wheel.

1 In making the cover It a blank of suitable sheet material such as stainless steel, brass or like cold workable material may be subjected to substantially the cold work drawing method set forth in my copending Patent No. 2,707,499 which includes drawing a sheet metal blank to provide'the crown portion 20, the indented or dished annular intermediate portion 21 and the outer annular portion 22, but with the outer marginal portion of the outer annular cover portion 22 arranged to be subjected to a plurality of further working steps. In this preliminarily drawn form of the blank, as shown in Figure 4, the margin of the cover is provided with an axially outwardly directed annular, generally U-shaped, axially inwardly opening axially elongated rib 35 with a radially inner leg merging into the adjacent surface of the cover portion '22 and .with an outer axial leg merging into the cover retaining flange 27 which initiallyis part of the margin of the blank and lies horizontally. In the drawing of the rib 35, it is cold worked to impart substantial hardnessand resiliency to the material thereof.

Thereafter, the laterally extending flange 27 is worked into axial direction as an extension of the radially outer side of the rib 35 and the retaining fingers trimmed in the flange are also cold worked into their axially extending position, and the finger terminals 29 bent into position.

According to the present invention the reenforcing and stop corrugations 31 are worked into the flange 27 by reworking the corrugations into the flange during the flange straightening step. This is depicted by comparison of the full line showing in Figure 4 with the dash line showing wherein it will be observed that the flange 27 is bent down toward straightened position wherein the stop corrugations 31 are worked out while the fingers 23 are formed. Since this effects cold working and hardening of the flange 27 and at the same time cold working and stretching and hardening of the corrugations 31, uniform- 1y throughout the circumference of the flange 27, uniform reenforcement and strong resilient resistance to radial deflection of the worked down flange 27 is attained.

After working of the flange 27 has been accomplished, as described, the partially finished cover is completed by bending the rib 35 laterally and radially outwardly through and beyond the circle of the flange 27 into position angular to the dished surface 21 of the cover whereby to increase the overall diameter of the cover and conceal the flange 27 therebehind. The steps by which this may be accomplished are shown in Figures 5 and 6.

First, the upstanding rib 35 may be folded laterally outwardly by stages as shown. As a first step in the collapsing and outwardly folding of the rib 35, it may be partially collapsed and bent out as shown in dash outline in Figure 5 and in full outline in Figure 6. Finally, the partially collapsed-fold rib 35 is entirely collapsed upon itself with the radially inner wall thereof providing the annular reenforcing marginal rib portion 23 of the cover and the radially outer leg of the rib providing the underturned flange 24.

In the collapsing end bending over of the annular rib 35, the axially outer ends of the reenforcing corrugations 31 will serve to afford a convenient annular fulcrum about which the bending of the outer leg of the rib proceeds, and toward which the inner leg of the rib is bent and then indented at the base end thereof to afford the annular reenforcing rib 32 contiguous the axially outer ends of the corrugations.

It will be appreciated that in the cold working to which the rib 35' is subjected not only in its initial formation but subsequently as it is bent radially outwardly and collapsed, and the cold working to which the axial flange 27 is subjected when it is straightened and as it is provided with the corrugations 31, as well as the working to which the finger extensions 28 and the terminals 2 are subjected, all adds up to an efiiciently hard, stiflly resilient cover marginal extremity and retaining flange and finger structure mutually coacting to effect the positive retaining grip of the retaining terminals 29 upon the rim flange when the cover is on the wheel.

It will be understood that modifications and variations may be effected without departing from the scope of the concepts of the present invention.

I claim as myinvention:

1. In a method of making from a sheet metal blank a single circular wheel cover or trim member wherein substantially the entire outer periphery of the blank is employed to form the periphery of and retaining means for the single member, the steps of centrally dishing the blank body to provide an annular generally axially extending dished surface, cold working the outer blank margin to form therein an annular rib of generally U- shaped cross-section and with a radially inner leg merging into said dished surface and with its other and outer leg merging into a cover retaining flange, working said flange into axially extending position and at circumferentially spaced intervals bending in said flange reenforcing corrugations running out at the edge of the flange, bending inner terminal extremities of the corru gations into turned reenforcing lips, bending said rib laterallyand radially outwardly through and beyond the circle of said flange into a position at an angle to said dished surface where-by to increase the overall diameter of the ensuing member and with said flange extending generally axially thereunder and radially inward thereof, and forming a portion of the flange to provide cover retaining means.

2. In a method of making from a sheet metal blank a single circular wheel cover or trim member wherein substantially the entire outer periphery of the blank is employed to form the periphery of and retaining means for the single member, the steps of centrally dishing the blank body to provide an annular generally axially extending dished surface, cold working the outer blank margin to form therein an annular rib of generally U- shaped cross-section and with a radially inner leg merging into said dished surface and with its other and outer leg merging into a cover retaining flange, working said flange into axially extending position, bending said rib laterally and radially outwardly through and beyond the circle of said flange into a position at an angle to said dished surface whereby to increase the overall diameter of the ensuing member and with said flange extending generally axially thereunder and radially inward thereof, working generally axial corrugations opening through the edge of the flange structure for reenforcing the flange structure, and forming a portion of the flange to provide cover retaining means.

3. In a method of making a wheel trim or cover, drawing a sheet metal blank to provide a body having an annular axially outwardly opening trough-like channel defining an axially inwardly directed dished rib and a narrow hollow rib-like channeled section opening rearwardly and projecting generally axially outwardly at the radially outer side of said first mentioned channeled rib and with a radially outwardly directed flange structure on the radially outer wall or leg of said section and inset relative to the ridge or peak of said section, turning said flange structure generally axially inwardly into extension of said radially outer wall leg of said section, substantially collapsing and radially outwardly bending said section to provide a marginal flange fold overlying said flange structure, and forming cover retaining means on said flange structure and working the flange structure to provide a plurality of circumferentially spaced axial corrugations running out through the inner terminal of the flange structure and cooperating with the retaining means for retaining the cover on a wheel to which the same may be applied.

4. In a method of making a wheel trim or cover, drawing a sheet metal blank to provide a body having an annular axially outwardly opening trough-like channel defining an axially inwardly directed dished rib and a narrow hollow rib-like channeled section opening rearwardly and projecting generally axially outwardly at the radially outer side of said first mentioned channeled rib and with a radially outwardly directed flange structure on the radially outer wall or leg of said section and inset relative to the ridge or peak of said section, trimming said flange structure to provide retaining finger extensions, turning said flange structure generally axially inwardly into extension of said radially outer wall leg of said section, working areas of the flange structure intermediate said retaining finger extensions into reenforcing corrugations, bending the terminals of the finger extensions to project generally radially outwardly for engagement with a flange of a wheel, and substantially collapsing and radially outwardly bending said section to provide a marginal flange fold overlying said flange structure.

5. The method of making a wheel cover from a single blank of sheet metal which comprises initially drawing a crown portion and a preliminary relatively narrow rib extending in the same direction as the crown portion and separated therefrom by an oppositely extending relatively large juncture rib, the margin of the blank being maintained substantially flat, trimming the margin of the blank to provide a plurality of radially outward retaining finger or clip extensions on the margin, working said margin of the blank axially into extensions of. the outer side of said narrow rib, corrugating the portions of the flange intermediate said extensions into resiliency enhancing radially outwardly bowed corrugations, and thereafter bending the narrow rib radially outwardly to place said extensions in axial position behind said narrow rib.

6. The method of making a wheel cover from a single blank of sheet metal which comprises initially drawing a crown portion and a preliminary relatively narrow rib extending in the same direction as the crown portion and separated therefrom by an oppositely extending relatively large juncture rib, the margin of the blank being maintained substantially flat, trimming the margin of the blank to provide a plurality of radially outward retaining finger or clip extensions on the margin, working said margin of the blank axially into extension of the outer side of said narrow rib, corrugating the portions of the flange intermediate said extensions into resiliency enhancing radially outwardly bowed corrugations, thereafter bending the narrow rib radially outwardly to place said extensions in axial position behind said narrow rib, and Working the bent over narrow rib into a reenforcing arched annular cover marginal rib.

7. The method of making a wheel cover from a single blank of sheet metal which comprises initially drawing a crown portion and a preliminary relatively narrow rib extending in the same direction as the crown portion and separated therefrom by an oppositely extending relatively large juncture rib, the margin of the blank being maintained substantially flat, trimming the margin of the blank to provide a plurality of radially outward retaining finger or clip extensions on the margin, working said margin of the blank axially into extension of the outer side of said narrow rib, corrugating the portions of the flange intermediate said extensions into resiliency enhancing radially outwardly bowed corrugations, thereafter bending the narrow rib radially outwardly to place said extensions in axial position behind said narrow rib, working the bent over narrow rib into a reenforcing arched annular cover marginal rib, and working an indented annular reenforcing rib in the cover for backing the finger flange adjacent the axially outer ends of the corrugations.

8. In a method of making a wheel cover or trim member, drawing a sheet metal blank into a circular body and in such drawing shaping a narrow annular hollow rib projecting in one axial direction and opening in the opposite axial direction and bounded on its radially inner side by an inner portion of the member and at its radially outer side by a radially outwardly projecting margin, trimming said margin of the member to provide a plurality of radially outwardly projecting retaining finger extensions, working said margin of the blank in said opposite axial direction to provide an axial extension flange of the outer side of said narrow rib, shaping terminals on said finger extensions, corrugating said flange extension other than in said finger extensions whereby to reinforce and enhance the resiliency of the flange extension, and bending said rib radially outwardly to place said corrugated flange extension and said finger extensions in axial position behind said outwardly bent rib.

References Cited in the file of this patent UNITED STATES PATENTS 2,660,479 Lyon Nov. 24, 1953 2,707,449 Lyon May 3, 1955 2,828,160 Lyon Mar. 25, 1958 

